Baxi Potterton BBU 15 HE manual

© Baxi Heating UK Ltd 2009 B a x i Bermuda BBU 15 HE Condensing Back Boiler Unit These Instructions must be read in conjunction with those for the separate Valor Dimension electric firefront. They include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. Installation & Servicing Instructions[...]

2 © Baxi Heating UK Ltd 2009 Natural Gas Baxi Bermuda BBU 15 HE G.C.No. 44 075 09 For use with the following electric firefronts: Valor Dimension Classica Brass, Pewter or Black BBU Firefront Valor Dimension Dream Gold, Chrome or Black BBU Firefront Valor Dimension Innova BBU Firefront Valor Dimension Regalia BBU Firefront Valor Dimension Nano Chr[...]

Installer Notification Guidelines 3 © Baxi Heating UK Ltd 2009 Choose Building Regulations Notification Route Contact your rele v ant Local A uthor ity Building Control (LABC) who will arrange an inspection or contact a gov er nment approv ed inspector LABC will record the data and will issue a cer tificate of compliance ‘Gas Safe Register’ wi[...]

Legislation 4 © Baxi Heating UK Ltd 2009 Codes of Practice, most recent version should be used In GB the following Codes of Practice apply: Standard Scope BS 6891 Gas Installation. BS 5546 Installation of hot water supplies for domestic purposes. BS 5449 Forced circulation hot water systems. BS 6798 Installation of gas fired hot water boilers. BS [...]

Safe Manual Handling 5 © Baxi Heating UK Ltd 2009 General The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance. Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shou[...]

6 © Baxi Heating UK Ltd 2009 1.0 Introduction 7 2.0 General Layout 8 3.0 Technical Data 10 4.0 System Details 11 5.0 Site Requirements 15 6.0 Boiler Internal Wiring 20 7.0 Installation 21 8.0 Completion & Commissioning 25 9.0 Annual Servicing 27 10.0 Changing Components 29 11.0 Setting the Gas Valve 33 12.0 Fault Finding 34 13.0 Short Parts Li[...]

1.0 Intr oduction © Baxi Heating UK Ltd 2009 1.1 Description 1. The Baxi Bermuda BBU 15 HE is a central heating boiler designed for installation within a builders opening in the living space of a dwelling. 2. The boiler is a fully automatic gas fired condensing boiler. It is room sealed and fan assisted. 3. The boiler output will automatically mod[...]

2.0 General Lay out 8 © Baxi Heating UK Ltd 2009 2.1 Layout (Fig. 3) 1. Automatic Air Vent 2. Flue Connection 3. Spark Generator 4. Spark & Sensing Electrodes 5. Heat Exchanger 6. Boiler Control Connector 7. Control Wiring Connector 8. Condensate Sump 9. Gas Cock 10. Condensate Pump 11. Fan 12. Drain 13. Return Connection 14. Air Sampling Poin[...]

9 © Baxi Heating UK Ltd 2009 2.0 General Lay out 2.2 Flue Kit (10m & 12.5m) (Fig. 3a) 1. Terminal Cap 2. Flue Duct Adaptor 3. Air Cowl 4. Air Duct Collar 5. Air Duct Clamp 6. Closure Plate 7. Boiler Adaptor 8. 60mm Ø Seal 9. Collar Securing Screws x 4 10. 100mm Ø Seal 11. 60mm Ø Flue Duct 12. 100mm Ø Air Duct 13. ‘C’ Clip 1 2 3 4 5 6 7[...]

10 © Baxi Heating UK Ltd 2009 Sedbuk Declaration For Bermuda BBU 15 HE The seasonal efficiency (SEDBUK) is 90.1% This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated has been certified by 0087. Appliance Category CAT I 2H Inlet Pressure (Natu[...]

4.0 System Details 11 © Baxi Heating UK Ltd 2009 4.1 Water Circulating Systems 1. The appliance is suitable for use on fully pumped systems ONLY which may be sealed or open vented. 2. The following conditions should be observed at all times: The static head must not exceed 30m of water. The static head must not be less than 1m of water. The boiler[...]

4.3 Pipework 1. The sizes of the flow and return pipes from the boiler should be determined by normal methods according to the requirements of the system. 2. It is recommended that the system is designed for a drop in temperature across the system of between 11& 20°C. 3. In systems using non-metallic pipework it is necessary to use copper pipe[...]

4.0 System Details 13 © Baxi Heating UK Ltd 2009 4.7 Sealed Systems (Figs. 6, 7 & 8) 1. Installation. The installation must comply with the requirements of BS 6798 and BS EN 12828. The British Gas publication “British Gas Specification for Domestic Wet Central Heating Systems” should also be consulted. 2. Pressure Relief Valve. A non-adjus[...]

4.0 System Details 14 © Baxi Heating UK Ltd 2009 4.7 Sealed Systems (cont) 4. Expansion Vessel. A diaphragm type expansion vessel to BS 4814:1 shall be fitted close to the inlet side of the pump. The connecting pipework should not be less than 15mm. Pipework connecting the expansion vessel should not incorporate valves of any sort. Methods of supp[...]

5.0 Site Requirements 15 5.1 Builders Opening (Fig. 9) 1. The boiler unit is designed to fit within a standard builders opening, the minimum dimensions of which are as shown. Height 570mm Width 584mm Depth 305mm 2. The opening should be soundly constructed of brick, pre-cast concrete or be a proprietary builders opening. 3. The base of the opening [...]

5.0 Site Requirements 16 © Baxi Heating UK Ltd 2009 5.5 Flue 1. The following guidelines indicate the general requirements for installation of flues. For GB recommendations are given in BS 5440 Part 1. For IE recommendations are given in the current edition of I.S. 813 “Domestic Gas Installations”. 2. Only one of the two available MULTIIFIT ve[...]

5.0 Site Requirements 17 © Baxi Heating UK Ltd 2009 5.6 Ventilation 1. No ventilation is required for the boiler in the room of installation. 5.7 Gas Supply (Fig. 11) 1. The gas installation should be in accordance with relevant standards. In GB this is BS 6891. In IE this is I.S. 813 “Domestic Gas Installations”. The connection at the applian[...]

5.0 Site Requirements 18 © Baxi Heating UK Ltd 2009 5.9 Condensate Drain - General Failure to install the condensate discharge pipework correctly will affect the reliable operation of the boiler. 1. Ensure the discharge of condensate complies with any national or local regulations in force. BS 6798 & Part H1 of the Building Regulations give fu[...]

19 © Baxi Heating UK Ltd 2009 5.0 Site Requirements 5.10 Condensate Disposal (cont.) 9. Ensure that the condensate can discharge freely (without blockage or restriction of the pipe) into the drain. 10. Examples are shown of condensate pipe methods of termination:- i) via an internal discharge branch (e.g. sink waste) - Fig. 13. ii) to an internal [...]

20 © Baxi Heating UK Ltd 2009 6.0 Boiler Internal Wiring 6.1 Boiler Internal Illustrated Wiring Diagram - brown - black - blue - white - yellow br bk b w y - green - green / y ellow - red g g/y r Control PCB X2 X3 X9 X501 12 12 3 3 4 4 5 5 678 9 X1 12 Central Heating NTC Flow Sensor Fan Gas V alve Overheat Thermostat Condensate Pump X400 X401 bk b[...]

7.0 Installation 21 © Baxi Heating UK Ltd 2009 INSTALLATION SEQUENCE There are 4 main elements to the installation of the Baxi Bermuda BBU 15 HE:- • Preparation of pipework & opening • Inserting the flue into the chimney • Siting & fixing the boiler • Fitting the terminal assembly The sequence in which these are performed may depen[...]

7.0 Installation 22 © Baxi Heating UK Ltd 2009 7.2 Flue System (cont.) 8. It is recommended that the Pull Cone Flue Adaptor (part no. 720111801) is used as shown to ease the fitting of the flue into the chimney and prevent damage to the adaptor. 9. The cone has two internal lugs that engage on the boiler adaptor in a bayonet action (Figs. 21 &[...]

7.0 Installation 23 © Baxi Heating UK Ltd 2009 7.2 Flue System (cont.) 16. Pass the air duct collar and air cowl over the 60mm flue duct (Fig. 28) and secure the collar to the closure plate with the screws supplied (Fig. 29). The air cowl will fit snugly over the collar. 17. Cut the protruding 60mm flue duct down so that 5 ribs are visible and fit[...]

7.0 Installation 24 © Baxi Heating UK Ltd 2009 7.3 Siting the Boiler IMPORTANT - This product should be lifted and handled by two people. Stooping should be avoided and protective equipment worn where necessary. Carrying & lifting equipment should be used as required, e.g. when installing on another floor. 1. Lift the boiler from the packing b[...]

25 © Baxi Heating UK Ltd 2009 8.0 Completion & Commissioning 8.1 Completion 1. Seal off any secondary openings within the builders opening after wrapping the gas and water pipes through the brickwork and within the opening itself. (B.S. 5871 Part 1). 2. Take the Boiler Control from the firefront packaging and connect it to the boiler (Fig. 38)[...]

26 © Baxi Heating UK Ltd 2009 8.0 Completion & Commissioning 8.2 Commissioning the Boiler (cont.) IMPORTANT : The combustion for this appliance has been checked, adjusted and preset at the factory for operation on the gas type specified on the appliance data plate. No measurement of the combustion is necessary. Do not adjust the air/gas ratio [...]

27 © Baxi Heating UK Ltd 2009 9.0 Annual Ser vicing Off Position Fig. 41 On Position Fig. 42 9.1 Annual Servicing 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person in accordance with B.S. 7967-4. 2. After servicing, complete the relevant Service Interval [...]

28 © Baxi Heating UK Ltd 2009 9.0 Annual Ser vicing 9.2 Annual Servicing - Inspection 1. Ensure that the boiler is cool. 2. Ensure that the gas supply to the boiler is isolated. 3. Operate the Reset switch (Fig. 41) to activate the condensate pump and then repeat. This will empty most of the condensate from the sump.9. Isolate the boiler from the [...]

29 © Baxi Heating UK Ltd 2009 10.0 Changing Components 10.1 Changing Components 1. To change any components on the back boiler it is necessary to remove the firefront. 2. Refer to the Installer Guide that accompanies the firefront for details of removal. 3. Ensure that the boiler is cool and that the electrical and gas supplies are isolated. 4. Af[...]

30 © Baxi Heating UK Ltd 2009 10.5 Fan (Fig. 49) 1. Disconnect the two plugs from the fan motor and remove the sensing pipe from between the gas valve and fan outlet. 2. Remove the gas feed pipe and washers, and extract the injector from the gas/air inlet manifold. 3. For ease of access disconnect the following:- a) 2 pin plug on NTC lead b) all w[...]

31 © Baxi Heating UK Ltd 2009 10.0 Changing Components 10.8 Gas Valve (Fig. 51) IMPORTANT: After replacing the valve the CO 2 must be checked and adjusted as detailed in Section 11.0 Setting the Gas Valve. Only change the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see Section 9.1 1. Disconnect[...]

32 © Baxi Heating UK Ltd 2009 10.9 PCB (Fig. 54) 1. Pull off the two control knobs and disengage the securing tabs of the cover. Undo the screws securing the PCB. 2. Draw the PCB forwards and disconnect the wiring. Transfer the two potentiometer drive pins to the new PCB and replace in reverse order of dismantling. 3. Ensure that the wiring connec[...]

33 © Baxi Heating UK Ltd 2009 11.0 Setting the Gas V alve 11.1 Setting the Gas Valve ( CO 2 check) IMPORTANT: The CO 2 must be only be checked and adjusted to set the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see Section 9.1 1. The combustion (CO 2 ) may be checked after running the boiler fo[...]

34 © Baxi Heating UK Ltd 2009 12.0 Fault Finding NOTE: When instructed to operate the reset button, press and hold for 5 seconds to reset the boiler. 12.1 Initial Fault Finding Checks 1. Check that gas, water and electrical supplies are available at the boiler. 2. Electrical supply = 230V ~ 50 Hz. Check the CH & DHW system. The preferred minim[...]

12.0 Fault Finding 35 © Baxi Heating UK Ltd 2009 Refer to Section 16.0 “Illustrated Wiring Diagram” for position of terminals and components Central Heating - Follow operational sequence Turn on Power Supply Display Illuminates Error 20 or 28 flashing Error 158 flashing Burner lights Error 110 flashing Error 131 flashing Turn Central Heating t[...]

12.0 Fault Finding 36 © Baxi Heating UK Ltd 2009 Fault Finding Solutions Sections Is there 230V at: Check all system wiring and pump Main terminals L and N Check electrical supply 1. NO Main terminal fuse Replace fuse Replace PCB Display illuminated 2. NO PCB - X1 connector terminals 1,2 Check wiring 3. NO NO A B 1. 2. C NO YES Fan connections cor[...]

12.0 Fault Finding 37 © Baxi Heating UK Ltd 2009 Check and correct if necessary 1. The mechanical set of the gas valve (CO2 values - see instruction) 2. Flame sensing electrode and lead connections 3. Flame sensing electrode position Flame current should be more than 0.5 μA Replace PCB YES Replace flame sensing electrode NO Check the gas supply p[...]

38 © Baxi Heating UK Ltd 2009 13.0 Short Par ts List Short Parts List Key Description Manufacturers No. Part No. A Burner Assy 720125701 B Injector 720126301 C Ignition Lead 720127501 D Gas Valve 720127001 E P.C.B 720125801 F Fan 5121447 G NTC Sensor 720126101 H Float Switch (Safety or Discharge) 720126201 I Safety Thermostat 720126401 J Spark Gen[...]

39 © Baxi Heating UK Ltd 2009 14.0 Notes[...]

40 © Baxi Heating UK Ltd 2009 14.0 Notes[...]

14.0 Notes 41 © Baxi Heating UK Ltd 2009[...]

GAS BOILER SYSTEM COMMISSIONING CHECKLIST CONTROLS Tick the appropriate boxes Time and T emperature Control to Heating Room Thermostat and Programmable Load/W eather Optimum Start r e m i T / r e m m a r g o r P Room Thermostat Compensation Control r e m i T / r e m m a r g o r P d n a t a t s o m r e h T r e d n i l y C r e t a W t o H o t l o r t[...]

SERVICE RECORD It is recommended that your heating system is serviced r egularly and that the appropriate Service Record is completed. Service Provider Before completing the appr opriate Service Record below , please ensure you have carried out the service as described in the manufacturer’ s instructions. Always use the manufacturer’ s specifi[...]

© Baxi Heating UK Ltd 2009 Comp N o 710161501 (7/09) 9.0 W arranty & Ser vice All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet. All goods are sold subject t[...]